Patent Application
20240083063
The present disclosure is directed to a scoring apparatus and methods for controlling the scoring apparatus. More specifically, the present disclosure is directed to a scoring apparatus and methods for setting axial position and gap dimension of a gap between one or more score blades and an anvil shaft of the scoring apparatus.
Operational and quality control of (back or top) scoring processes is highly desirable in manufacturing. Control schemes for this process have been in large part manual in nature. Although control schemes involving the use of electrical actuators has recently gained popularity, control schemes using feedback to achieve fully automated control have received little attention. Additionally, when switching between different materials or substrates for the scoring process, different control schemes are required. However, such control schemes require operators to make process modification determinations, typically requiring shutting down operation of the production line, which is inefficient, disruptive, and costly.
Therefore, there is a need in the art for a scoring apparatus and control schemes that do not suffer from the above shortcomings.
In an example embodiment, a method for setting an axial position and gap dimension of a gap between one or more score blades and an anvil shaft of a rotary scoring device includes providing a control system including a controller, at least one sensor, and at least one adjusting device actuated by the control system, and actuating the at least one adjusting device in response to the at least one sensor sensing a deviation from a desired state, thereby setting the axial position or the gap dimension between the one or more score blades and the anvil shaft. The method further includes actuating the at least one adjusting device is achieved as a result of the control system operating in a closed feedback loop. The method further includes sensing by the at least one sensor occurring with or without disruption of operation of the rotary scoring device.
In another example embodiment, a method for operating a rotary scoring device includes feeding a material web to be treated into a feed of the rotary scoring device, sending data associated with at least one characteristic property of the material web, measured by at least one sensor, to a control unit, operating an adjusting device to adjust an axial position between two score blades, operating a motor to adjust a gap dimension between the two score blades and an anvil shaft, and setting the axial position and the gap dimension between the two score blades and the anvil shaft to a desired location to treat the material web. The motor includes an encoder to send a feedback signal, to determine at least one of speed, RPM, count, distance or direction.
In yet another example embodiment, a method for setting a gap of a rotary die cutting system includes providing a control system including a controller, at least one sensor, a first adjusting device, and a second adjusting device, each actuated by the control system, actuating the first adjusting device in response to the at least one sensor sensing a deviation from a desired state, thereby setting a gap dimension between a rotary die cutting device and a counter pressure cylinder of a rotary die cutting device, and actuating the second adjusting device in response to the at least one sensor sensing a deviation from a desired state, thereby setting an axial position and a gap dimension between one or more score blades and an anvil shaft of a rotary scoring device. The method further includes the rotary scoring device positioned in series with respect to the rotary die cutting device. The method further includes actuating the second adjusting device is achieved as a result of the control system operating in a closed feedback loop. The method further includes sensing by the at least one sensor occurring with or without disruption of operation of the rotary die cutting system.
In yet another example embodiment, a rotary scoring device includes a frame including at least one blade holder, containing a score blade therein, and an anvil shaft, the at least one blade is separated from the anvil shaft by a gap, and a control system including a controller, at least one sensor, and a first adjusting device and a second adjusting device actuated by the control system. The first and second adjusting devices are operably connected to the at least one blade holder to adjust an axial position.
Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.
The present invention provides a scoring process that is less prone to human error and reduces downtime/costs associated with setup, improves safety by reducing operators from working inside of the scoring machines during operation, eliminates blade damage (during the setup process), reduces scrap of materials, extends blade life & produces higher quality and consistent product, and/or increases throughput by eliminating stoppages to address the aforementioned problems. In addition, lateral positioning and scoring depth cut formed in a material passing between one or more blades and an anvil roller of a rotary scoring device is automatically controlled by employing a saved material library and job features. As such, repeatable and accurate results of the lateral positioning and cut- to depths of the blades from the saved material library and job saved features is achieved.
As described herein, “scoring” is an industry known process of partially cutting into a sheet or material to allow a subsequent bending, folding, creasing, tearing or peeling of the sheet or material. That is, rather than cutting entirely through the sheet or material, scoring leaves a blade impression, indent, or partial cut at a single stress point. The score produced typically only penetrates or cuts partially through the material which reduces the thickness at the stress point, or fully through one or more layers of a multi-layer material while leaving one or more layers intact.
In some implementations, the exemplary rotary scoring system performs a kiss cut such that the cut material stays married to a support material. That is, a kiss cut is to cut only one layer of material, leaving the support material untouched, wherein the end user can remove the cut material out from the support material. The cut goes just deep enough to penetrate the top surface leaving the backer support material intact. Coupons, sticker sheets or pull-back reveals are great examples where kiss cutting technique is used.
The exemplary rotary scoring system described herein performs a top (fully cut through the material face leaving the liner intact) or back (fully cut through the material liner leaving the face intact) scoring.
In other implementations, sensor(s) 21, 22, 23, 24, as controlled by controller 36, measures the thickness of the material 30 that includes a face web material 31a and a backing web material 31b remaining subsequent to being directed between the blade holders 12 and the anvil shaft 14, which thickness measurement may occur subsequent to or prior to removal of the face web material 31a. Subsequently, a database of historical runs (stored in storage 39, as shown in
It is to be understood that a deviation from a desired state as a result of a change in thickness of at least one of the backing web 31b and overlying web 31a may also be due to thermal expansion of web material or of equipment, a change in humidity of an environment surrounding rotary scoring device 10, a change in a tension gradient of at least one of the backing web 31b and overlying web 31a, a cut depth of score blades 83 and the material 30, and an impression quality of score blades 83 and material 30 or other reasons.
Each of the sensors 21, 22, 23, 24 is connected to the controller 36 via respective conduits 71, 72, 73, 74, which may be hardwired or wireless communicated therebetween. For example, the controller 36 can communicate with the sensors 21, 22, 23, 24 over a serial connection or the controller 36 can wirelessly communicate with the sensors 21, 22, 23, 24, such as Bluetooth, Wi-Fi, RF transmission, GPS, or the like.
Sensors 21, 22, 23, 24 are used to provide a closed feedback loop, utilizing the sensors to permit continuous or undisrupted operation of the scoring process.
In some implementations, information from one or all sensors of one or all embodiments is transmitted to and from controller 36, including an IoT framework, an onsite network infrastructure or on a local media located in controller 36.
Referring to
Referring to
The bottom housing portion 56 houses a motor encoder 72 (or rotary encoder) mounted to an electric motor 74 that provides closed loop feedback signals, controlled by controller 36, by tracking the position of a motor shaft 79. The encoder 72 is used to provide high speed and with high accuracy to the blade holder 12. In other implementations, in addition to positioning, the encoder 72 can send a feedback signal, to determine speed, RPM, count, distance, and/or direction.
In one implementation, the accuracy of the scoring can be approximately 0.0004 inch, dependent upon the material used. By way of example, a tested accuracy of 0.004 inch can be achieved for a vinyl face material and a test accuracy of 0.0002 can be achieved for a polypropylene face material. In other implementations, the scoring can be independent upon the material used. For example, when using a motor with an integrated gear box and encoder an accuracy can be achieved including up to 4×10-6 inches.
Near a lower portion of the bottom housing portion 56, a blade housing 81 is attached thereto. The blade housing 81 holds the score blade 83 (
The electromagnetic transducer 61, as controlled by controller 36 via conduit 78 or via wireless communication therebetween, measures linear displacement or movement of the blade holders 12. Subsequently, controller 36 operates the electric motor 67 via conduit 77 or via wireless communication therebetween to drive the belt drive 66 and move the blade holder 12 into a desired lateral location. Similarly, the controller 36 operates the motor encoders 72 via conduits 75, 76 or via wireless communication therebetween to move the respective score blades 83 into a desired cut-to depth for scoring. In some implementations, a database of historical runs (stored in storage 39) corresponding with the same or similar material 30, for example, is used to lookup what gap 16 was used to produce desirable results in the past. An algorithm in the controller 36 determines the signal to send to the motor encoder 72 in the blade holders 12 via conduits 75, 76 or via wireless communication therebetween in order to achieve the same gap 16 that was returned from the database in storage 39. It should be appreciated that the database may include parameters such as, material name, material type, material serial number or identifier, material caliper, material basis weight, material tensile strength, material elasticity, machine measurements, individual score blade diameter, machine settings, or conditions at the time a parameter was saved, for example.
The storage system 39 comprises any storage media, or group of storage media, readable by processor 38, and capable of storing software and data. The storage system 39 can include volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. The storage system 39 may store a set of processor instructions or algorithm, which when executed by the controller 36 enables automatic operation of the rotary scoring system 1. Examples of the non-volatile memory may include, but are not limited to, a flash memory, a Read Only Memory (ROM), a Programmable ROM (PROM), Erasable PROM (EPROM), and Electrically EPROM (EEPROM) memory. Examples of volatile memory may include, but are not limited Dynamic Random Access Memory (DRAM) and Static Random-Access memory (SRAM).
In one implementation, the controller 36 provides control instructions to the scoring device 10 via conduits 77, 78 or wireless communication therebetween, that is executed by a belt drive motor controller which controls movements of the belt drive 61. By way of example, the control instructions may move the two blade holders 12 via the belt drive 61 laterally to their respective desired positions. The control instructions may further provide instructions to the motor encoder 72 to control the movement of the blade 83 to a desired cut depth position. More specifically, the controller 36 provides instructions to the motor encoder 72 to control the motor 74 for movements of the shaft 79 which then controls the blade 83 in a linear movement (i.e., up-and-down).
In some implementation, the controller 36 may receive control instructions from an input device 50 which may include a display 51 to display information executable by the controller 36, which will be described in detail later. The display 51 is a graphical user interface (i.e., touchscreen display) that can be displayed on a device, such as a computer, a laptop, a television, a smart phone, etc. In one implementation, the controller 36 is adapted or configured to receive historical run data or updates of selected material to operate the scoring function.
In other implementations, the controller 36 processes input nodes of a neural network 100 (
For example, referring to
In some implementations, the neural network 100 permits different weightings in the hidden layer 103 portion to accommodate different preferences of different operators. In other words, such preferences could be changed, corresponding to the working hours of the different operators, and could be performed manually or automatically, such as upon the operator “clocking in” for a work shift.
In some implementations, the neural network operates utilizing one or more sensors sensing parameters in an absence of or prior to separation of the material 30, the backing web 31b, and the matrix web 31a from one another, and wherein sensing by the one or more sensors occurring with or without disruption of operation of the rotary blade scoring 1.
Feedback to the automated control process may include specifications or measurements pertaining to the scoring device 10, material being cut (e.g., webs 31a, 31b) or other process parameters affecting the quality of the score.
Example embodiments described herein provide a closed feedback loop or automated control process that is a significant improvement over current manual processes, in which an operator utilizing an exemplary blade impression image guide 74 (
In some implementations, controller 36 employs AI methods to control the rotary scoring device 10. In other implementations, controller 36 employs machine learning methods to control the rotary scoring device 10. In other implementations, controller 36 employs deep learning methods to control the rotary scoring device 10. Accordingly, present exemplary machine learning as described herein learns how to classify scoring by using convolutional filters to feed imagery grayscale intensity values into a neural network. For example, output of the neural network is assigned to actuators that perform blade clearance & parallel adjustments. The machine learns optimal settings by assignment of appropriate weights & biases for all perceptrons in each hidden layer.
In some implementations, the neural network is deployed with the ability to perform training on demand at the location of deployment or remotely from an offsite location, both occurring either during operation or not.
In some implementations, a custom neural network is constructed for isolated or combined parameters present within the control unit 32 or process (i.e., customer neural networks for each different type of web material, each different scoring device, each different blade, each different cut depth setting, each different line speed setting, etc.).
Referring now to
To illustrate an exemplary operation using an exemplary sample material (i.e., 6 in. wide), the user selects the modify interface 206c from the Pattern selection block 206 of Main tab 202a, as shown in
Alternatively, if a new sample material is used to be treated, the user selects the new interface 206b from the Pattern selection block 206 and enters the parameters or configuration, i.e., type of material, thickness of material, blade holder positions, cut-to depth, etc. for operation. Subsequently, the user may save the parameters or configuration to the library to be used in future use.
Next, referring to
Surprisingly, results including the deep learning method used for impression characterization handles both transparent and opaque materials with equal effectiveness. Another result is the high accuracies that are attainable with little training.
In some implementations, the present rotary scoring system can be merged in a rotary die cutting system that comprises a rotary die cutting device including a die cutting cylinder and a counter pressure cylinder separated from the die cutting cylinder by a gap, as described in U.S. patent application Ser. No. 17/217,226, and herein incorporated by reference. In addition to controlling the rotary scoring system, the control unit may correspondingly, or alternatively separately control both the rotary die cutting device and the rotary scoring system to actuate an adjusting device(s) to adjust for the axial position and/or gap dimension. In one implementation, the rotary die cutting system is positioned in series with respect to the rotary scoring system.
The articles “a” and “an,” as used herein, mean one or more when applied to any feature in embodiments of the present disclosure described in the specification and claims. The use of “a” and “an” does not limit the meaning to a single feature unless such a limit is specifically stated. The article “the” preceding singular or plural nouns or noun phrases denotes a particular specified feature or particular specified features and may have a singular or plural connotation depending upon the context in which it is used. The adjective “any” means one, some, or all indiscriminately of whatever quantity.
“At least one,” as used herein, means one or more and thus includes individual components as well as mixtures/combinations.
The transitional terms “comprising”, “consisting essentially of” and “consisting of”, when used in the appended claims, in original and amended form, define the claim scope with respect to what unrecited additional claim elements or steps, if any, are excluded from the scope of the claim(s). The term “comprising” is intended to be inclusive or open-ended and does not exclude any additional, unrecited element, method, step or material. The term “consisting of” excludes any element, step or material other than those specified in the claim and, in the latter instance, impurities ordinarily associated with the specified material(s). The term “consisting essentially of” limits the scope of a claim to the specified elements, steps or material(s) and those that do not materially affect the basic and novel characteristic(s) of the claimed disclosure. All materials and methods described herein that embody the present disclosure can, in alternate embodiments, be more specifically defined by any of the transitional terms “comprising,” “consisting essentially of,” and “consisting of.”
Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that, if an element is referred to as being “connected” or “coupled” to another element, it can be directly connected, or coupled, to the other element or intervening elements may be present. In contrast, if an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).
Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper” and the like) may be used herein for ease of description to describe one element or a relationship between a feature and another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, for example, the term “below” can encompass both an orientation that is above, as well as, below. The device may be otherwise oriented (rotated 90 degrees or viewed or referenced at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.
Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, may be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
While the disclosure has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
This application claims priority to U.S. Provisional Application 63/375,483 entitled “Scoring Device and Methods for Setting Axial Position and Gap Dimension,” filed Sep. 13, 2022, the disclosure being incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63375483 | Sep 2022 | US |
